Composite concrete and cement-wood fiber plank

ABSTRACT

A composite laminated concrete and cement-wood fiber plank consisting of a peripheral metal frame defining a substantially rectangular solid and having two edges with tongues and two edges with grooves, concrete in said frame, a cement-wood fiber plank portion having a first face extending slightly into said frame and a second face facing away from said frame and a border proximate the first face on which said frame rests, said concrete penetrating voids in the cement-wood fiber plank portion to effect a bond between the concrete and the cement-wood fiber portion, with the portion of the metal frame adjacent the cementwood fiber plank portion being of a slightly smaller perimeter than the perimeter of the cement-wood fiber plank portion and the perimeter of the portion of the frame above the tongues and the grooves.

United States Patent 7 [72] Inventor Charles A. Martin Williamsville,NY. [21 Appl. No. 861,820 [22] Filed Sept. 29, 1969 [45] Patented Dec.7, 1971 [73] Assignee Martin Fireproofing Corporation Buffalo, N.Y.

[54] COMPOSITE CONCRETE AND CEMENT-WOOD FIBER PLANK 9 Claims, 4 DrawingFigs.

[52] US. Cl 161/37, 52/309,52/595, l6l/44, l6l/l6l [5i] Int.Cl B32b3/10, B32b 3/02 [50] Field oiSearch l6l/37, 43-44, l59l6l; 52/593, 595,309

[56] References Cited UNITED STATES PATENTS 2,142,305 l/l939 Davis....52/593 X 2,064,996 12/1936 Venzie 52/595 X ml! W007 2,083,725 6/1937Manske et al 52/595 X 3,353,322 ll/l967 Guddal 52/309 X 3,372,520 3/1968Hensel 52/595 X FOREIGN PATENTS 774,049 5/1957 Great Britain l6l/l 6|Primary Examiner- Philip Dier Anomey- Sommer, Weber & Gastel ABSTRACT: Acomposite laminated concrete and cementwood fiber plank consisting of aperipheral metal frame defining a substantially rectangular solid andhaving two edges with tongues and two edges with grooves, concrete insaid frame, a cement-wood fiber plank portion having a first faceextending slightly into said frame and a second face facing away fromsaid frame and a border proximate the first face on which said framerests, said concrete penetrating voids in the cementwood fiber plankportion to effect a bond between the concrete and the cement-wood fiberportion, with the portion of the metal frame adjacent the cement-woodfiber plank por tion being of a slightly smaller perimeter than theperimeter of the cement-wood fiber plank portion and the perimeter ofthe portion of the frame above the tongues and the grooves.

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SHEET 2 OF 2 PATENTED [1E0 new NW. m x I I I NW, -mm mw Em fix] mm) umum m \ww Iv/W M1 COMPOSITE CONCRETE AND CEMENT-WOOD FIBER PLANK Thepresent invention relates to an improved plank construction which is alamination of steel edged concrete with a facing of cement-wood fiber.

It is the primary object of the present invention to provide an improvedplank construction which is a laminate of steeledged concrete andcement-wood fiber which is fabricated in a highly efi'rcient manner.

Another object of the present invention is to provide an improved plankconstruction which is a laminate of concrete with a cement-wood fiberfacing which provides an extremely pleasing appearance by presenting acontinuous decorative expanse of cement-wood fiber to the inside of aroom which completely obscures both the cement portion of the plank andthe metal edging associated therewith.

A further object of the present invention is to provide an improvedplank construction which is a composite of steel-edged concretelaminated with a facing of cement-wood fiber which, in addition tohaving the structural strength of concrete, is installable as a unit ina single step to additionally provide a decorative ceiling, thedesirable acoustical properties of cement-wood fiber, effectiveshielding of the steel edge from direct flame, and highly efiicientinsulation. Other objects and attendant advantages of the presentinvention will readily be perceived hereafter.

The improved plank construction of the present invention comprises aperipheral frame defining a substantially rectangular solid and havingtwo edges with tongues and two edges with grooves, concrete in theperipheral frame and bonded thereto with the concrete having a firstside and a second side, a cement-wood fiber plank portion having voidstherein and having a first face and a second face, with the edge of saidfirst face of the cement-wood fiber portion providing a base forreceiving the frame with a portion of said first face of the cement-woodfiber portion extending into the frame to provide a locking engagementtherewith, and the concrete penetrating the voids in the cement-woodfiber plank portion to effect a bond therewith.

The present invention will be more fully understood when the followingportions of the specification are read in conjunction with theaccompanying drawings wherein:

FIG. 1 is a plan view of the composite laminated concrete andcement-wood fiber plank;

FIG. 2 is a fragmentary cross-sectional view taken substantially alongline 22 of FIG. 1;

FIG 3 is a fragmentary cross-sectional view taken substantially alongline 33 of FIG. 1 and showing the relationship between the plank shownin FIG. 1 and adjacent planks with Y which it is assembled; and

FIG. 4 is a fragmentary cross-sectional view taken substantially alongline 4-4 of FIG. 3 and showing the manner in which a clip is secured tothe plank.

The composite laminated concrete and cement-wood fiber plank includes ametal frame 11 mounted on the periphery of a concrete plank portion 12which has its lower face 13 bonded to the upper face 14 of a cement-woodfiber plank portion 15, the bonding being effected by the difiusion of acertain amount of the concrete at the interface into the voids of thecement-wood fiber plank portion 15.

The cement-wood fiber plank portion 15 is fabricated from extra longwood fibers up to about l8 inches long and roughly about one-sixteenthinch by one thirty-second inch rectangularly in cross section, whichhave been chemically processed against deterioration, coated with cementby mixing them in a cement slurry, and bonded under pressure to providea cast porous plank having numerous random voids between felted Portlandcement-bonded fibers which is therefore lightweight (having a density ofabout 36 pounds per cubic foot), strong, noncombustible, and hasexcellent thermal insulating and acoustical properties. This material isknown under the trademark FIBROPLANK of the Martin FireproofingCorporation and is well known in the art.

After plank portion 15 has been formed in the foregoing manner, it issized by milling a border thereon which includes surfaces 16, 17, 18 and19 thereon to provide a level portion on which sides 20, 21, 22 and 23of frame 11 rest. The plank portion 15, after the foregoing sizingoperation, is left with a central protuberance 24 of a size which fitssnugly between flanges 25, 26, 27 and 28, respectively, adjacent sides20, 21, 22 and 23, respectively, of the assembled frame. Because of thisrelationship, the frame 11 can be mounted accurately in its finalposition on plank portion 15.

Thereafter metal-reinforcing mesh 29 is laid into frame 11 as far downas it will go and the concrete which forms body portion 12 is pouredinto the frame and troweled to cause top surface 30 to be flat as shownin FIGS. 2 and 3. The troweling, as well as the weight of the concrete,will cause a certain amount of the concrete proximate the interfacebetween the body portion 12 and the plank 15 to penetrate the voids ofthe latter, and when it dries, it will form the bond which securelyattaches the plank 15 to the remainder of the structure. It will also benoted that the concrete also fully fills the frame 11, as can be seenfrom FIGS. 2 and 3, the flanges 25-28 and 31-34 securely locking theframe 11 to the body 12. At this point it is to be noted that theflanges 31, 32, 33 and 34, as well as the flanges 25, 26, 27 and 28extend for substantially the entire length of the metal edge memberwhich they form a part of.

The frame 11 consists of metal edge members 35, 36, 37 and 38 which aresuitably joined to each other as by welding at their junctions. Edgemembers 37 and 38 are of a construction which includes grooves 39 and40, respectively. Edge members 35 and 36 are of a construction whichincludes tongues 41 and 42, respectively. Edge members 35, 36, 37 and 38include upper side portions 43, 44, 45 and 46, respectively, which lieabove the tongue and groove portions and define the outer upperperipheral side of the concrete portion of the plank. Edge members 35,36, 37 and 38 also include lower side portions 47, 48, 49 and 50,respectively, which define the periphery of the lower portion of theconcrete portion of the plank below the ridges and the grooves, as canbe seen from FIGS. 2 and 3.

The perimeter of upper portions 43, 44, 45 and 46 is greater than theperimeter of portions 47, 48, 49 and 50. In other words, the upper edgesextend outwardly a bit more than the lower edges on all sides. Thus, ascan be seen from FIG. 3, all of the upper edge portions of adjacentplanks are in abutting relationship when they are mated by means of thetongues and grooves and the lower edge portions will be spaced asufficient amount so as to accommodate the clips such as 51 and theheads 52 of the nails which secure the clips to the lower edge portion49 of the metal edges, the clips 51 being for the purpose of securingthe planks to purlins 53, as shown in FIG. 4.

As can be seen from FIGS. 2 and 3, the plank portion 15 has a perimeterwhich is equal to the perimeter of the upper edge portions of the metalframe. In other words, the perimeter of sides 54, 55, 56 and 57 of plankportion 15 is the same as the perimeter of upper edge portions 43, 44,45 and 46 of the frame and in line therewith. Therefore, when adjacentplanks are mated, as shown in FIG. 3, the edge portions of adjacentplank portions 15 will abut each other to cover or obscure the spacessuch as 58 between the lower edge portions of the frames. However, sincethe plank portion 15 is somewhat compressible, it will compress in theareas where clips 51 are located, thereby to accommodate such clips. Ascan be seen, the edges of the planks 15 are chamfered at 59, 60, 61 and62 so as to provide a pleasing configuration where adjacent planks meet.

It will be appreciated of course that bonding agents other than Portlandcement can be used for bonding the wood fibers if desired.

The improved plank of the present invention incorporates effectiveinsulation, acoustic properties and a decorative ceiling in a plank unithaving a concrete portion. This has a number of advantages, The improvedplank of the present invention can be installed in a single step in asimple and highly efficient manner, thereby obviating the costly andinefficient prior practice of either installing separate insulation onthe top of the concrete and/or a decorative ceiling below the concrete.Furthermore, because the cement-wood fiber portion of the plank providesa continuous expanse on the inside of the room, there is no directconductive path between the inside of the room and the outside of theroof through the concrete or the steel frame which bounds the concrete,thereby providing highly efficient insulation and flame retardation, aswell as the aforementioned decorative ceiling. In addition, since thereis no separate insulation on the top of the concrete which forms the topof a roof deck, the exposed concrete portion will be capable of takingthe abuse of the elements during construction, as well as permittingtraffic thereon during the construction process.

I claim:

1. A composite laminated concrete and cement-wood fiber plankconstruction comprising a peripheral frame defining a substantiallyrectangular solid, concrete in said peripheral frame and bonded theretowith said concrete having a first face and a second face, a cement-woodfiber plank portion including voids therein and having a third face anda fourth face with said third face of said cement-wood fiber plank incontiguous relationship to said first face of said concrete, and edgeportions on said third face in contiguous relationship with said frame,said concrete penetrating said voids in said cement-wood fiber plankportion to effect a bond therebetween, said second face of saidcement-wood fiber plank portion and said fourth face of said concretedefining the outer faces of said plank, said frame including two sideshaving tongues and two sides having grooves, with said tongues andgrooves being located substantially on the central portions of the sidesof said frame, said frame including an upper side portion above saidtongues and grooves and a lower side portion below said tongues andgrooves, said upper side portions extending laterally outwardly beyondsaid lower side portions to provide spaces between lower side portionsof assembled adjacent planks for accommodating mounting clips, saidcement-wood fiber plank having a peripheral dimension which isapproximately equal to the peripheral dimension of said upper sideportions and in line therewith so as to conceal said spaces between saidlower side portions of assembled adjacent planks.

2. A composite laminated concrete and cement-wood fiber plankconstruction comprising a peripheral frame defining a substantiallyrectangular solid, concrete in said peripheral frame and bonded theretowith said concrete having a first face and a second face, a cement-woodfiber plank portion including voids therein and having a third face anda fourth face with said third face of said cement-wood fiber plank incontiguous relationship to said first face of said concrete, edgeportions on said third face in contiguous relationship with said frame,said concrete penetrating said voids in said cementwood fiber plankportion to effect a bond therebetween, said second face of saidcementwood fiber plank portion and said fourth face of said'concretedefining the outer faces of said plank, said frame including outer edgeportions substantially coextensive with said first face of saidconcrete, said outer edge portions defining an inner perimeter, and aprotuberance on said cement-wood fiber plank portion having an outerperimeter of substantially the same size as said inner perimeter, saidprotuberance extending into said inner perimeter to locate said frame onsaid cement-wood fiber plank portion.

3. A composite laminated concrete and cement-wood fiber plankconstruction as set forth in claim 2 wherein said frame includes twosides having tongues and two sides having grooves, with said tongues andgrooves being located substantially on the central portion of the sidesof said frame, said frame including an upper side portion above saidtongues and grooves and a lower side portion below said tongues andgrooves, said upper side portions extending laterally outwardly beyondsaid lower side portions to provide spaces between lower side portionspfassembled adjacent lanks for accommodating mounting clips, saidcement-wood rber plank having a peripheral dimension which isapproximately equal to the peripheral dimension of said upper sideportions and in line therewith so as to conceal said spaces between saidlower side portions of assembled adjacent planks.

4. A composite laminated concrete and cement-wood fiber plankconstruction as set forth in claim 2 wherein said edge portions of saidthird face are in abutting relationship with said frame.

5. A composite laminated concrete and cement-wood fiber plankconstruction as set forth in claim 4 including a metal reinforcing meshembedded in said concrete proximate said first face thereof.

6. A composite laminated concrete and cement-wood fiber plankconstruction as set forth in claim 5 wherein said frame includes twosides having tongues and two sides having grooves, with said tongues andgrooves being located substantially on the central portion of the sidesof said frame, said frame including an upper side portion above saidtongues and grooves and a lower side portion below said tongues andgrooves, said upper side portions extending laterally outwardly beyondsaid lower side portions to provide spaces between lower side portionsof assembled adjacent planks for accommodating mounting clips, saidcement-wood fiber plank having a peripheral dimension which isapproximately equal to the peripheral dimension of said upper sideportions and in line therewith so as to conceal said spaces between saidlower side portions of assembled adjacent planks.

7. A composite laminated concrete and cement-wood fiber plankconstruction comprising a peripheral frame defining a substantiallyrectangular solid, concrete in said peripheral frame and bonded theretowith said concrete having a first face and a second face, a cement-woodfiber plank portion including voids therein and having a third face anda fourth face with said third face of said cement-wood fiber plank incontiguous relationship to said first face of said concrete, and edgeportions on said third face in contiguous relationship with said frame,means bonding said cement-wood fiber plank portion relative to saidconcrete, said second face of said cement-wood fiber plank portion andsaid fourth face of said concrete defining the outer faces of saidplank, said frame including outer edge portions substantiallycoextensive with said first face of said concrete, said outer edgeportions defining an inner perimeter, and a protuberance on saidcement-wood fiber plank portion having an outer perimeter ofsubstantially the same size as said inner perimeter, said protuberanceextending into said inner perimeter to locate said frame on saidcement-wood fiber plank portion.

8. A composite laminated concrete and cement-wood fiber plankconstruction as set forth in claim 7 wherein said edge portions of saidthird face are in abutting relationship with said frame.

9. A composite laminated concrete and cement-wood fiber plankconstruction comprising a peripheral frame defining a substantiallyrectangular solid, said frame having an inner portion and an outerportion, concrete within said inner portion of said peripheral frame andbonded thereto with said concrete having a first face, a cement-woodfiber plank portion including voids therein and having a second face anda third face with said second face of said cement-wood fiber plank beingin contiguous relationship to said first face of said concrete, saidconcrete penetrating said voids in said cementwood fiber plank portionto effect a bond therebetween in the area of said first and secondfaces, said cement-wood fiber plank portion including a portion lyingoutside of said peripheral frame and covering a portion of said outerportion of said frame thereby to obstruct said outer portion of saidframe from view when said plank is installed, and said third face ofsaid cement-wood fiber plank portion defining an outer surface of saidplank.

2. A composite laminated concrete and cement-wood fiber plankconstruction comprising a peripheral frame defining a substantiallyrectangular solid, concrete in said peripheral frame and bonded theretowith said concrete having a first face and a second face, a cement-woodfiber plank portion including voids therein and having a third face anda fourth face with said third face of said cement-wood fiber plank incontiguous relationship to said first face of said concrete, edgeportions on said third face in contiguous relationship with said frame,said concrete penetrating said voids in said cement-wood fiber plankportion to effect a bond therebetween, said second face of saidcement-wood fiber plank portion and said fourth face of said concretedefining the outer faces of said plank, said frame including outer edgeportions substantially coextensive with said first face of saidconcrete, said outer edge portions defining an inner perimeter, and aprotuberance on said cement-wood fiber plank portion having an outerperimeter of substantially the same size as said inner perimeter, saidprotuberance extending into said inner perimeter to locate said frame onsaid cement-wood fiber plank portion.
 3. A composite laminated concreteand cement-wood fiber plank construction as set forth in claim 2 whereinsaid frame includes two sides having tongues and two sides havinggrooves, with said tongues and grooves being located substantially onthe central portion of the sides of said frame, said frame including anupper side portion above said tongues and grooves and a lower sideportion below said tongues and grooves, said upper side portionsextending laterally outwardly beyond said lower side portions to providespaces between lower side portions of assembled adjacent planks foraccommodating mounting clips, said cement-wood fiber plank having aperipheral dimension which is approximately equal to the peripheraldimension of said upper side portions and in line therewith so as toconceal said spaces between said lower side portions of assembledadjacent planks.
 4. A composite laminated concrete and cement-wood fiberplank construction as set forth in claim 2 wherein said edge portions ofsaid third face are in abutting relationship with said frame.
 5. Acomposite laminated concrete and cement-wood fiber plank construction asset forth in claim 4 including a metal reinforcing mesh embedded in saidconcrete proximate said first face thereof.
 6. A composite laminatedconcrete and cement-wood fiber plank construction as set forth in claim5 wherein said frame includes two sides having tongues and two sideshaving grooves, with said tongues and grooves being locatedsubstantially on the central portion of the sides of said frame, saidframe including an upper side portion above said tongues and grooves anda lower side portion below said tongues and grooves, said upper sideportions extending laterally outwardly beyond said lower side portionsto provide spaces between lower side portions of assembled adjacentplanks for accommodating mounting clips, said cement-wood fiber plankhaving a peripheral dimension which is approximately equal to theperipheral dimension of said upper side portions and in line therewithso as to conceal said spaces between said lower side portions ofassembled adjacent planks.
 7. A composite laminated concrete andcement-wood fiber plank construction comprising a peripheral framedefining a substantially rectangular solid, concrete in said peripheralframe and bonded thereto with said concrete having a first face and asecond face, a cement-wood fiber plank portion including voids thereinand having a third face and a fourth face with said third face of saidcement-wood fiber plank in contiguous relationship to said first face ofSaid concrete, and edge portions on said third face in contiguousrelationship with said frame, means bonding said cement-wood fiber plankportion relative to said concrete, said second face of said cement-woodfiber plank portion and said fourth face of said concrete defining theouter faces of said plank, said frame including outer edge portionssubstantially coextensive with said first face of said concrete, saidouter edge portions defining an inner perimeter, and a protuberance onsaid cement-wood fiber plank portion having an outer perimeter ofsubstantially the same size as said inner perimeter, said protuberanceextending into said inner perimeter to locate said frame on saidcement-wood fiber plank portion.
 8. A composite laminated concrete andcement-wood fiber plank construction as set forth in claim 7 whereinsaid edge portions of said third face are in abutting relationship withsaid frame.
 9. A composite laminated concrete and cement-wood fiberplank construction comprising a peripheral frame defining asubstantially rectangular solid, said frame having an inner portion andan outer portion, concrete within said inner portion of said peripheralframe and bonded thereto with said concrete having a first face, acement-wood fiber plank portion including voids therein and having asecond face and a third face with said second face of said cement-woodfiber plank being in contiguous relationship to said first face of saidconcrete, said concrete penetrating said voids in said cement-wood fiberplank portion to effect a bond therebetween in the area of said firstand second faces, said cement-wood fiber plank portion including aportion lying outside of said peripheral frame and covering a portion ofsaid outer portion of said frame thereby to obstruct said outer portionof said frame from view when said plank is installed, and said thirdface of said cement-wood fiber plank portion defining an outer surfaceof said plank.